Ultraviolet-curable resin material for pattern transfer and magnetic recording medium manufacturing method using the same

ABSTRACT

According to one embodiment, this invention uses an ultraviolet-curable resin material for pattern transfer containing 80 to 95 wt % of isobornyl acrylate, 1 to 20 wt % of trifunctional acrylate, and 0.5 to 6 wt % of a polymerization initiator.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2009-060930, filed Mar. 13, 2009, the entire contents of which are incorporated herein by reference.

BACKGROUND

1. Field

One embodiment of the present invention relates to a method of manufacturing a magnetic recording medium having discrete tracks on the surface of a magnetic recording layer and, more particularly, to an ultraviolet-curable resin material to be used when transferring a discrete track shape.

2. Description of the Related Art

Recently, the nano-imprinting techniques are attracting attention in various fields in order to further increase the density and accuracy.

For example, applications to semiconductors, optical elements, magnetic recording media, and the like are being examined.

As a magnetic recording medium, a discrete track medium is attracting attention. In this discrete track medium, magnetic interference between adjacent recording tracks is reduced by separating the adjacent tracks by grooves or guard bands made of a nonmagnetic material in order to further increase the density.

When manufacturing this discrete track medium, discrete track patterns of a magnetic layer can be formed by applying the nano-imprinting technique by using a stamper. When magnetic layer patterns corresponding to servo area signals are formed together with recording track patterns by imprinting, it is possible to obviate the servo track writing step required in the manufacture of the conventional magnetic recording media. This leads to a cost reduction.

As the process of forming discrete track patterns as described above, a process of transferring resist patterns from an Ni stamper by, e.g., high-pressure imprinting or thermal imprinting has been used. Unfortunately, this process is unsuitable for mass-production because the life of the Ni stamper is short. Also, when the data density is increased to make tracks finer, resist patterns cannot be well transferred.

From the foregoing, the use of optical nano-imprinting is attracting attention as another nano-imprinting technique.

To transfer patterns onto a resist on a discrete track medium by using optical nano-imprinting, a resin stamper is first duplicated from an Ni stamper (mother stamper) by injection molding, and bonded in a vacuum to an uncured ultraviolet-curable resin layer to be used as a resist. This method is found to be able to reduce the cost and suitable for micropatterning.

The characteristics required of the ultraviolet-curable resin to be transferred onto the above-mentioned discrete track medium are the property of coating onto the medium, the viscosity, the curing property, the property of separation from the resin stamper, the resistance against etching for processing transferred patterns, and the cure shrinkage. The thickness of the ultraviolet-curable resin must be sufficient for imprinting with respect to the height of the three-dimensional structure of transfer patterns. For later processing steps, however, the amount of residue of the ultraviolet-curable resin after imprinting is preferably small. Therefore, the coating film thickness of the ultraviolet-curable resin layer is desirably 60 nm or less.

An example of the ultraviolet-curable resin for radical polymerization is an ultraviolet-curable resin obtained by mixing an initiator, an oligomer having a vinyl (acryloyl) group, and a monomer (see, e.g., non-patent reference 1). However, when an oligomer is mixed in an ultraviolet-curable resin, the viscosity increases, and this makes it difficult to decrease the coating film thickness to 60 nm or less.

Also, as disclosed in Jpn. Pat. Appln. KOKAI Publication No. 2008-19292, an example of the ultraviolet-curable resin for nano-imprinting is an ultraviolet-curable resin to which a surfactant is added to improve the coating property and the property of separation. If the amount of surfactant is too large, however, curing inhibition readily occurs, the curing time tends to prolong, or the magnetic recording medium often deteriorates.

In addition, since the coating film thickness must be very small, i.e., 60 nm or less, film thickness control is difficult to perform unless the viscosity of the ultraviolet-curable resin is 15 cP or less.

If a monofunctional monomer alone is cured, the curing property of the film degrades. On the other hand, if the functional order is increased, the film cures, but the cure shrinkage readily increases.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A general architecture that implements the various feature of the invention will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention.

FIGS. 1A, 1B, 1C, and 1D are views showing a pattern transfer method to be used in the present invention;

FIG. 2 is a view showing a magnetic recording/reproduction apparatus for performing recording and reproduction on a magnetic recording medium;

FIGS. 3A, 3B, 3C, 3D, 3E, 3F, 3G, 3H, 3I, 3J, and 3K are views showing an example of a discrete magnetic recording medium manufacturing method; and

FIG. 4 is a view showing an outline of the arrangement of a transfer pattern sample evaluation apparatus.

DETAILED DESCRIPTION

Various embodiments according to the invention will be described hereinafter with reference to the accompanying drawings. In general, according to one embodiment of the invention, an ultraviolet-curable resin material for pattern transfer is provided, which contains isobornyl acrylate represented by formula (I) below, trifunctional acrylate, and a polymerization initiator. The composition is that the content of isobornyl acrylate is 80 to 95 wt %, that of the trifunctional acrylate is 1 to 20 wt %, and that of the polymerization initiator is 0.5 to 6 wt %.

In the present invention, the viscosity of the ultraviolet-curable resin material is adjusted to 15 cP or less by mixing isobornyl acrylate, the trifunctional acrylate, and the polymerization initiator at a predetermined mixing ratio, so a coating film having a small uniform thickness of 60 nm or less can be formed. This makes it possible to reduce the residue of the imprinted ultraviolet-curable resin. Also, the ultraviolet-curable resin material for pattern transfer having the above-mentioned composition are superior in ultraviolet curing property, property of separation after curing, etching resistance, and cure shrinkage. When using this ultraviolet-curable resin material for pattern transfer, therefore, accurate pattern transfer can be performed from a stamper.

Isobornyl acrylate has a relatively low viscosity of 9 cP and a relatively high glass transition point Tg. Also, isobornyl acrylate has a high etching resistance because it has an alicyclic structure. When a material containing two components, i.e., this isobornyl acrylate and a polymerization initiator was used as the ultraviolet-curable resin material for pattern transfer, the hardness of the cured film was insufficient. This similarly happened when a monofunctional monomer, a bifunctional monomer, and isobornyl acrylate were combined. When a trifunctional monomer was combined, the hardness of the cured film was sufficient while the etching resistance remained high. The viscosity often increases when using a polyfunctional monomer larger than a trifunctional monomer.

Also, a magnetic recording medium manufacturing method includes bonding, in a vacuum, the surface of a magnetic recording layer of a magnetic recording medium including a data area and servo area, and a three-dimensional pattern surface of a resin stamper, with a coating layer of an uncured ultraviolet-curable resin material for pattern transfer being interposed between them,

curing the coating layer of the uncured ultraviolet-curable resin material by irradiating the coating layer with ultraviolet rays,

separating the resin stamper to form, on one surface of the magnetic recording medium, a cured ultraviolet-curable resin material layer onto which a three-dimensional pattern is transferred, and

performing dry etching by using the cured ultraviolet-curable resin material layer as a mask, thereby forming a three-dimensional pattern on the surface of the magnetic recording layer,

wherein the ultraviolet-curable resin material for pattern transfer contains 80 to 95 wt % of isobornyl acrylate, 1 to 20 wt % or trifunctional acrylate, and 0.5 to 6 wt % of a polymerization initiator.

In addition to the acrylates and polymerization initiator described above, an additive such as an adhesive can be mixed at a ratio of 1 wt % or less in the ultraviolet-curable resin material for pattern transfer of the present invention.

The ultraviolet-curable resin material for pattern transfer of the present invention can have a viscosity of 9 to 15 cP at 25° C.

As the trifunctional acrylate, it is possible to use, e.g.,

trimethylolpropane triacrylate,

trimethylolpropane PO-modified triacrylate

-   -   (number of propoxy groups [POs]: 2, 3, 4, 6),

trimethylolpropane EO-modified triacrylate

-   -   (number of ethoxy groups [EOs]: 3, 6, 9, 15, 20),

tris(2-hydroxyethyl)isocyanurate triacrylate,

pentaerythritol triacrylate,

pentaerythritol EO-modified triacrylate,

EO-modified glycerin triacrylate,

propoxylated (3) glyceryl triacrylate,

highly propoxylated (5.5) glyceryl triacrylate,

trisacryloyloxyethyl phosphate, and

ε-caprolactone-modified tris(acryloxyethyl)isocyanurate.

As the polymerization initiator, it is possible to use, e.g., an alkylphenone-based photopolymerization initiator, acylphosphine oxide-based polymerization initiator, titanocene-based polymerization initiator, oxime ester-based photopolymerization initiator, or oxime ester acetate-based photopolymerization initiator.

Practical examples of the above-mentioned polymerization initiators are

2,2-dimethoxy-1,2-diphenylethane-1-on (Irgacure 651 manufactured by Ciba Specialty Chemicals),

1-hydroxy-cyclohexyl-phenyl-ketone (Irgacure 184 manufactured by Ciba Specialty Chemicals), and

2-hydroxy-2-methyl-1-phenyl-propane-1-on (Darocur 1173 manufactured by Ciba Specialty Chemicals).

Other examples are Irgacure 2959, Irgacure 127, Irgacure 907, Irgacure 369, Irgacure 379, Darocur TPO, Irgacure 819, Irgacure 784, Irgacure OXE01, Irgacure OXE02, and Irgacure 754 (all are manufactured by Ciba Specialty Chemicals).

It is possible to select an optimum polymerization initiator in accordance with the wavelength of a lamp for use in UV irradiation.

As the lamp for use in UV irradiation, it is possible to use, e.g., a high-pressure mercury lamp, metal halide lamp, or xenon flash lamp.

An outline of a pattern transfer method to be used in the present invention will be explained below with reference to FIGS. 1A to 1D.

FIGS. 1A to 1D illustrate the transfer of patterns onto one surface of a medium substrate. As shown in FIG. 1A, a medium substrate 51 is set on a spinner 41. As shown in FIG. 1B, while the medium substrate 51 is spun together with the spinner 41, an ultraviolet-curable resin (2P resin) is dropped from a dispenser 42 and spin-coated. As shown in FIG. 1C, in a vacuum chamber 81, one surface of the magnetic recording medium 51 and a pattern surface of a transparent stamper 71 are bonded in a vacuum with a 2P resin layer (not shown) being interposed between them. As shown in FIG. 1D, the 2P resin layer is cured by emitting UV radiation from a UV light source 43 through the transparent stamper 71 at atmospheric pressure. After the step shown in FIG. 1D, the transparent stamper 71 is separated.

Examples of a magnetic disk substrate usable in the present invention are a glass substrate, an Al-based alloy substrate, a ceramic substrate, a carbon substrate, an Si single-crystal substrate having an oxidized surface, and a substrate obtained by forming an NiP layer on the surface of any of these substrates. As the glass substrate, amorphous glass or crystallized glass can be used. Examples of the amorphous glass are soda lime glass and alumino silicate glass. An example of the crystallized glass is lithium-based crystallized glass. As the ceramic substrate, it is possible to use a sintered product mainly containing aluminum oxide, aluminum nitride, or silicon nitride, or a material formed by fiber-reinforcing the sintered product. Plating or sputtering is used to form the NiP layer on the substrate surface.

When manufacturing a perpendicular magnetic recording medium, a so-called perpendicular double-layered medium can be formed by forming a perpendicular magnetic recording layer on a soft magnetic underlayer (SUL) on a substrate. The soft magnetic underlayer of the perpendicular double-layered medium passes a recording magnetic field from a recording magnetic pole, and returns the recording magnetic field to a return yoke placed near the recording magnetic pole. That is, the soft magnetic underlayer performs a part of the function of a recording head; the soft magnetic underlayer applies a steep perpendicular magnetic field to the recording layer, thereby increasing the recording efficiency.

An example of the soft magnetic underlayer usable in the present invention is a high-k material containing at least one of Fe, Ni, and Co. Examples of the material are FeCo-based alloys such as FeCo and FeCoV, FeNi-based alloys such as FeNi, FeNiMo, FeNiCr, and FeNiSi, FeAl-based and FeSi-based alloys such as FeAl, FeAlSi, FeAlSiCr, FeAlSiTiRu, and FeAlO, FeTa-based alloys such as FeTa, FeTaC, and FeTaN, and FeZr-based alloys such as FeZrN.

As the soft magnetic underlayer, it is also possible to use a material having a microcrystal structure such as FeA10, FeMgO, FeTaN, or FeZrN containing 60 at % or more of Fe, or a material having a granular structure in which fine crystal grains are dispersed in a matrix.

As another material of the soft magnetic underlayer, it is possible to use a Co alloy containing Co and at least one of Zr, Hf, Nb, Ta, Ti, and Y. The content of Co can be 80 at % or more. An amorphous layer is readily formed when a film of the Co alloy is formed by sputtering. The amorphous soft magnetic material has none of magnetocrystalline anisotropy, a crystal defect, and a grain boundary, and hence has superb soft magnetism. It is also possible to reduce the noise of the medium by using the amorphous soft magnetic material. Favorable examples of the amorphous soft magnetic material are CoZr-based, CoZrNb-based, and CoZrTa-based alloys.

Another underlayer may also be formed below the soft magnetic underlayer in order to improve the crystallinity of the soft magnetic underlayer or improve the adhesion to the substrate. As the underlayer material, it is possible to use Ti, Ta, W, Cr, Pt, an alloy containing any of these materials, or an oxide or nitride of any of these materials.

An interlayer made of a nonmagnetic material can be formed between the soft magnetic underlayer and perpendicular magnetic recording layer. The interlayer interrupts the exchange coupling interaction between the soft magnetic underlayer and recording layer, and controls the crystallinity of the recording layer. As the interlayer material, it is possible to use Ru, Pt, Pd, W, Ti, Ta, Cr, Si, an alloy containing any of these materials, or an oxide or nitride of any of these materials.

To prevent spike noise, it is possible to divide the soft magnetic underlayer into a plurality of layers, and antiferromagnetically couple these layers with 0.5- to 1.5-nm-thick Ru films being sandwiched between them. Also, the soft magnetic layer can be coupled by exchange coupling with a hard magnetic film having in-plane anisotropy such as CoCrPt, SmCo, or FePt, or a pinning layer made of an antiferromagnetic material such as IrMn or PtMn. To control the exchange coupling force, a magnetic layer such as a Co layer or a nonmagnetic layer such as a Pt layer can be stacked above and below the Ru layer.

As the perpendicular magnetic recording layer usable in the present invention, it is possible to use a material mainly containing Co, containing at least Pt, containing Cr as needed, and further containing an oxide (e.g., silicon oxide or titanium oxide). In this perpendicular magnetic recording layer, the magnetic crystal grains can form a pillar structure. In the perpendicular magnetic recording layer having this structure, the orientation and crystallinity of the magnetic crystal grains are favorable. As a consequence, a signal-to-noise ratio (SNR) suitable for high-density recording can be obtained. The amount of oxide is important to obtain the above structure. The content of the oxide can be 3 to 12 mol %, and can also be 5 to 10 mol %, with respect to the total amount of Co, Pt, and Cr. When the content of the oxide in the perpendicular magnetic recording layer falls within the above range, the oxide deposits around the magnetic grains, so the magnetic grains can be isolated and downsized. If the content of the oxide exceeds the above range, the oxide remains in the magnetic grains and deteriorates the orientation and crystallinity of the magnetic grains. Furthermore, the oxide deposits above and below the magnetic grains. Consequently, the pillar structure in which the magnetic grains vertically extend through the perpendicular magnetic recording layer is often not formed. On the other hand, if the content of the oxide is less than the above range, the magnetic grains are insufficiently isolated and downsized. As a result, noise increases in recording and reproduction, and this often makes it impossible to obtain a signal-to-noise ratio (SNR) suited to high-density recording.

The content of Pt in the perpendicular magnetic recording layer can be 10 to 25 at %. When the Pt content falls within the above range, a uniaxial magnetic anisotropy constant Ku necessary for the perpendicular magnetic recording layer is obtained. In addition, the crystallinity and orientation of the magnetic grains improve. Consequently, a thermal decay characteristic and recording/reproduction characteristic suited to high-density recording are obtained. If the Pt content exceeds the above range, a layer having the fcc structure is formed in the magnetic grains, and the crystallinity and orientation may deteriorate. On the other hand, if the Pt content is less than the above range, it is often impossible to obtain Ku, i.e., a thermal decay characteristic suitable for high-density recording.

The content of Cr in the perpendicular magnetic recording layer can be 0 to 16 at %, and can also be 10 to 14 at %. When the Cr content falls within the above range, it is possible to maintain high magnetization without decreasing the uniaxial magnetic anisotropy constant Ku of the magnetic grains. Consequently, a recording/reproduction characteristic suited to high-density recording and a sufficient thermal decay characteristic are obtained. If the Cr content exceeds the above range, the thermal decay characteristic worsens because Ku of the magnetic grains decreases. In addition, the crystallinity and orientation of the magnetic grains worsen. As a consequence, the recording/reproduction characteristic tends to worsen.

The perpendicular magnetic recording layer can contain one or more additive elements selected from B, Ta, Mo, Cu, Nd, W, Nb, Sm, Tb, Ru, and Re, in addition to Co, Pt, Cr, and the oxide. These additive elements can promote the downsizing of the magnetic grains, or improve the crystallinity and orientation of the magnetic grains. This makes it possible to obtain a recording/reproduction characteristic and thermal decay characteristic more suitable for high-density recording. The total content of these additive elements can be 8 at % or less. If the total content exceeds 8 at %, a phase other than the hcp phase is formed in the magnetic grains, and this disturbs the crystallinity and orientation of the magnetic grains. As a result, it is often impossible to obtain a recording/reproduction characteristic and thermal decay characteristic suited to high-density recording.

Other examples of the material of the perpendicular magnetic recording layer are a CoPt-based alloy, a CoCr-based alloy, a CoPtCr-based alloy, CoPtO, CoPtCrO, CoPtSi, and CoPtCrSi. As the perpendicular magnetic recording layer, it is also possible to use a multilayered film containing Co and an alloy mainly containing at least one element selected from the group consisting of Pt, Pd, Rh, and Ru. It is further possible to use a multilayered film such as CoCr/PtCr, CoB/PdB, or CoO/RhO obtained by adding Cr, B, or O to each layer of the former multilayered film.

The thickness of the perpendicular magnetic recording layer can be 5 to 60 nm, and can also be 10 to 40 nm. A perpendicular magnetic recording layer having a thickness falling within this range is suited to a high recording density. If the thickness of the perpendicular magnetic recording layer is less than 5 nm, the reproduction output becomes too low, so the noise component often becomes higher than the reproduction output. On the other hand, if the thickness of the perpendicular magnetic recording layer exceeds 40 nm, the reproduction output becomes too high and tends to distort the waveform. The coercive force of the perpendicular magnetic recording layer can be 237,000 A/m (3,000 Oe) or more. If the coercive force is less than 237,000 A/m (3,000 Oe), the thermal decay resistance tends to decrease. The perpendicular squareness ratio of the perpendicular magnetic recording layer can be 0.8 or more. If the perpendicular squareness ratio is less than 0.8, the thermal decay resistance often decreases.

A protective layer can be formed on the perpendicular magnetic recording layer.

The protective layer prevents the corrosion of the perpendicular magnetic recording layer, and also prevents damages to the medium surface when a magnetic head comes in contact with the medium. Examples of the material of the protective layer are materials containing C, SiO₂, and ZrO₂. The thickness of the protective layer can be 1 to 10 nm. When the thickness of the protective layer falls within the above range, the distance between the head and medium can be decreased. This is suitable for high-density recording.

The surface of the perpendicular magnetic recording medium can be coated with a lubricant, e.g., perfluoropolyether, alcohol fluoride, or fluorinated carboxylic acid.

FIG. 2 is a view showing a magnetic recording/reproduction apparatus for performing recording and reproduction on the magnetic recording medium.

This magnetic recording apparatus includes, in a housing 61, a magnetic recording medium 62, a spindle motor 63 for rotating the magnetic recording medium 62, a head slider 64 including a recording/reproduction head, a head suspension assembly (a suspension 65 and actuator arm 66) for supporting the head slider 64, a voice coil motor 67, and a circuit board.

The magnetic recording medium 62 is attached to and rotated by the spindle motor 63, and various digital data are recorded by the perpendicular magnetic recording method. The magnetic head incorporated into the head slider 64 is a so-called composite head, and includes a write head having a single-pole structure and a read head using a GMR film or TMR film. The suspension 65 is held at one end of the actuator arm 66, and supports the head slider 64 so as to oppose it to the recording surface of the magnetic recording medium 62. The actuator arm 66 is attached to a pivot 68. The voice coil motor 67 is formed as an actuator at the other end of the actuator arm 64. The voice coil motor 67 drives the head suspension assembly to position the magnetic head in an arbitrary radial position of the magnetic recording medium 62. The circuit board includes a head IC, and generates, e.g., a voice coil motor driving signal, and control signals for controlling read and write by the magnetic head.

An address signal and the like can be reproduced from the processed magnetic recording medium by using this magnetic disk apparatus.

A magnetic disk in which the track density was 325 kTPI (tracks per inch, equivalent to a track pitch of 78 nm) in a data zone having a radius of 9 to 22 mm was manufactured by using the method of the present invention.

To manufacture the magnetic disk having this servo area, imprinting is performed using a stamper having three-dimensional patterns corresponding to magnetic layer patterns on the magnetic disk. Note that the surface of the three-dimensional patterns of the magnetic layer formed by imprinting and subsequent processing may also be planarized by burying a nonmagnetic material in recesses.

A method of manufacturing the magnetic disk of this embodiment will be explained below.

First, a stamper was manufactured.

An Si wafer having a diameter of 6 inches was prepared as a substrate of a master as a template of the stamper. On the other hand, resist ZEP-520A available from Zeon was diluted to half with anisole, and the solution was filtered through a 0.05-μm filter. The Si wafer was spin-coated with the resist solution and prebaked at 200° C. for 3 minutes, thereby forming a resist layer about 50 nm thick.

An electron beam lithography system having a ZrO/W thermal field emission type electron gun emitter was used to directly write desired patterns on the resist onto the Si wafer at an acceleration voltage of 50 kV. This lithography was performed using a signal source that synchronously generates signals for forming servo patterns, burst patterns, address patterns, and track patterns, signals to be supplied to a stage driving system (a so-called X-θ stage driving system including a moving mechanism having a moving axis in at least one direction and a rotating mechanism) of the lithography system, and an electron beam deflection control signal. During the lithography, the stage was rotated at a constant linear velocity (CLV) of 500 mm/s, and moved in the radial direction as well. Also, concentric track areas were written by deflecting the electron beam for every rotation. Note that the feeding speed was 7.8 nm per rotation, and one track (equivalent to one address bit width) was formed by ten rotations.

The resist was developed by dipping the Si wafer in ZED-N50 (available from Zeon) for 90 seconds. After that, the Si wafer was rinsed as it was dipped in ZMD-B (available from Zeon) for 90 seconds, and dried by air blow, thereby manufacturing a resist master (not shown).

A conductive film made of Ni was formed on the resist master by sputtering. More specifically, pure nickel was used as a target. After a chamber was evacuated to 8×10⁻³ Pa, the pressure was adjusted to 1 Pa by supplying argon gas, and sputtering was performed in the chamber for 40 seconds by applying a DC power of 400 W, thereby forming a conductive film about 10 nm thick.

The resist master having this conductive film was dipped in a nickel sulfamate plating solution (NS-160 available from Showa Chemical Industry), and Ni electroforming was performed for 90 minutes, thereby forming an electroformed film about 300 μm thick. The electroforming bath conditions were as follows.

Electroforming Bath Conditions

Nickel sulfamate: 600 g/L

Boric acid: 40 g/L

Surfactant (sodium lauryl sulfate): 0.15 g/L

Solution temperature: 55° C.

pH: 4.0

Current density: 20 A/dm²

The electroformed film and conductive film were separated together with the resist residue from the resist master. The resist residue was removed by oxygen plasma ashing. More specifically, plasma ashing was performed for 20 minutes by applying a power of 100 W in a chamber in which the pressure was adjusted to 4 Pa by supplying oxygen gas at 100 mL/min.

As shown in FIG. 3A, a father stamper 1 including the conductive film and electroformed film as described above was obtained. After that, electroforming was further performed to duplicate a mother stamper 2 as shown in FIG. 3B. An injection molding stamper was obtained by removing unnecessary portions of the mother stamper 2 by a metal blade.

As shown in FIG. 3C, a resin stamper 3 was duplicated from the mother stamper 2 by using an injection molding apparatus manufactured by Toshiba Machine. As the molding material, cyclic olefin polymer Zeonor 1060R available from Zeon was used. However, polycarbonate material AD5503 available from Teijin Chemicals may also be used.

Then, a magnetic disk was manufactured.

A magnetic recording layer was formed by sputtering on a disk substrate made of doughnut-like glass 1.8 inches in diameter shown in FIG. 3G. A 3-nm-thick metal mask layer was stacked on this magnetic recording layer. Examples of a metal usable as the metal mask layer are Ag, Al, Au, C, Cr, Cu, Ni, Pt, Pd, Ru, Si, Ta, Ti, Zn, and alloys (e.g., CrTi, CoB, CoPt, CoZrNb, NiTa, NiW, Cr—N, SiC, and TiO_(x)) containing these metals. When using Si or Cu among these metals, the property of separation from the resin stamper and the processability tend to improve. The film thickness of the metal mask layer is determined by the processability, and can be as small as possible. In this embodiment, a 3-nm-thick Cu layer was stacked on the magnetic recording layer.

After a surface protection layer 6 was formed on a magnetic recording layer 5 as shown in FIG. 31, a resist 7 made of an ultraviolet-curable resin material was formed by spin coating at a rotational speed of 10,000 rpm.

As shown in FIG. 3C, the resin stamper 3 was bonded to the ultraviolet-curable resin resist 7 on the surface of the disk substrate by vacuum bonding, and the resin was cured by ultraviolet irradiation. After that, the resin stamper 3 was separated as shown in FIG. 3D.

In a three-dimensional pattern formation process performed by ultraviolet imprinting, the resist residue remains on the bottoms of pattern recesses.

Then, the resist residue on the bottoms of pattern recesses was removed by RIE using oxygen gas. As shown in FIG. 3E, the magnetic recording layer was etched by Ar ion milling by using the patterns of the resist 7 as masks. Subsequently, as shown in FIG. 3F, the resist patterns were removed by oxygen RIE. In addition, a carbon protective layer (not shown) was formed on the entire surface. After that, the manufactured magnetic disk was coated with a lubricant.

In the magnetic disk medium described above, the magnetic recording layer was etched to the bottom in a portion where no resist mask was formed. However, it is also possible to stop Ar ion milling halfway to obtain a medium having projections and recesses. Alternatively, it is possible to obtain a medium by imprinting a stamper onto a resist on a substrate without initially forming any magnetic layer, making the substrate shape three-dimensional by etching or the like, and then forming a magnetic film. Furthermore, in any medium including the above-mentioned media, the grooves may also be filled with a certain nonmagnetic material.

A resin stamper was duplicated by the above-mentioned method by using one Ni stamper, and ultraviolet-curable resin resist mask transfer was performed. 100 magnetic disks were duplicated for each ultraviolet-curable resin.

A resin stamper was duplicated by the above-mentioned method by using one Ni stamper, and ultraviolet-curable resin resist mask transfer was performed.

The ultraviolet-curable resin was evaluated for five items, i.e., the viscosity, curing property, property of separation, Ar sputter etching rate, and repeatable run-out (RRO).

The viscosity of the ultraviolet-curable resin was measured using a rotary viscometer (TVE-22LT manufactured by Toki Sangyo).

The curing property was evaluated after transfer by wiping up the resin with cloth wetted by ethanol. The evaluation was ⊚ when there was no change, ◯ when there were two or more fine scratches, Δ when there were three or more scratches, and x when the wiped portion entirely peeled off.

The property of separation was evaluated as ◯ when no 2P resin remained on the resin stamper after separation, Δ when the 2P resin slightly remained, and x when the 2P resin remained in a wide area.

The Ar sputter etching rate was measured by performing plasma etching in an Ar ambient at an Ar pressure of 1 Pa and an RF power of 100 W for 200 seconds by using 51A Sputtering Equipment manufactured by Shubaura Mechatronics. Before and after the etching, the film thickness of the ultraviolet-curable resin was measured by using Dektak 6M Stylus Surface Profiler manufactured by Ulvac. The etching rate was calculated by normalizing the difference between the film thicknesses before and after the etching by the etching time. The higher the etching resistance, the higher the processability when using the ultraviolet-curable resin. Therefore, the etching rate can be made as low as possible. For example, the etching rate was set at 0.25 nm/s or less as a reference.

The RRO is an effective means for checking the cure strain of the ultraviolet-curable resin. As the strain increases, the roundness of transferred patterns decreases, and the RRO tends to degrade. An evaluation apparatus for use in this evaluation is DDU-1000 manufactured by Pulstec.

First, an ultraviolet-curable resin transfer pattern sample was prepared for RRO evaluation. A glass plate having an inner diameter of 12.01 mm, an outer diameter of 32.00 mm, and a thickness of 0.6 mm was spin-coated with KBM503 available from Shin-Etsu Chemical. In the same manner as in a normal magnetic recording medium transfer/separation process, the coating film was coated with an ultraviolet-curable resin, pattern transfer was performed using a resin stamper, and the resin stamper was separated from the glass plate.

The RRO was evaluated by applying a laser from the side opposite to the transfer side of the ultraviolet-curable resin. The RRO is favorable when it is 1 nm or less.

An apparatus for checking the RRO of three-dimensional patterns will be explained below.

FIG. 4 is a block diagram showing an outline of the arrangement of the RRO evaluation apparatus for checking the RRO.

A semiconductor laser source 120 is used as a light source. The wavelength of the exit light is in, e.g., the violet wavelength band within the range of 400 to 410 nm. Exit light 110 from the semiconductor laser source 120 is collimated into parallel light by a collimator lens 121, and this parallel light enters an objective lens 124 through a polarizing beam splitter 122 and λ/4 plate 123. After that, the light is transmitted through a substrate of sample S, and concentrated on a substrate surface in which grooves are formed. The numerical aperture (to be referred to as the NA hereinafter) of the laser changes in accordance with the medium as an object. For example, the NA is about 0.5 to 0.7 for this sample when using an evaluation method by which the laser is transmitted through the interior of a 0.6-mm-thick transfer pattern sample. On the other hand, when using a sample made of a non-transmitting material or when playing back the surface of a sample, it is possible to adjust the NA to 0.85 or more, or insert an aberration correcting plate equivalent to a 0.6-mm-thick resin material between the laser and sample. Reflected light 111 from an information recording layer of the transfer pattern sample is transmitted through the substrate of transfer pattern sample S again, transmitted through the objective lens 124 and λ/4 plate 123, and reflected by the polarizing beam splitter 122. After that, the reflected light 111 enters a photodetector 127 through a condenser lens 125.

A light-receiving unit of the photodetector 127 is normally divided into a plurality of portions, and each light-receiving portion outputs an electric current corresponding to the light intensity. The output electric current is converted into a voltage by an I/V amplifier (current-voltage converter) (not shown), and the voltage is input to an arithmetic circuit 140. The arithmetic circuit 140 performs an arithmetic operation on the input voltage signal, thereby generating a tilt error signal, HF signal, focusing error signal, and tracking error signal. The tilt error signal is used to perform tilt control. The HF signal is used to reproduce information recorded on optical disk D. The focusing error signal is used to perform focusing control. The tracking error signal is used to perform tracking control.

The objective lens 124 can be driven in the vertical direction, disc radial direction, and tilt direction (radial and/or tangential direction) by an actuator 128, and is controlled to trace information tracks on transfer pattern sample S by a servo driver 150.

Note that in this evaluation apparatus, the wavelength of the semiconductor laser is in the range of 400 to 410 nm as an example. However, the present invention is not limited to this, and the wavelength can also be shorter. Note also that in this evaluation apparatus, the groove track pitch of the transfer pattern sample can be made smaller than, e.g., 0.4 μm. When the semiconductor laser has a long wavelength, the groove track pitch of the transfer pattern sample must be larger than 0.4 μm. The track pitch can be determined by the laser spot diameter. When performing tracking by using the push-pull method of the evaluation apparatus, the groove track pitch of the transfer pattern sample can be 0.5 to 1.2 times the laser spot diameter. The laser spot diameter can be represented by λ/NA. For example, when the laser wavelength is 405 nm and the NA is 0.65, the groove track pitch can be 0.31 to 0.75 μm. Also, when using, e.g., a fixed laser having a wavelength of 355 nm and an NA of 0.85, the laser spot diameter is 0.42 μm, so a minimum track pitch can be 0.2 μm. If the track pitch is too large, a dummy area expands, and the laser spot diameter of the evaluation apparatus tends to increase, so coarse evaluation is often performed on a data area. Therefore, the track pitch can be as small as possible. On the other hand, a laser wavelength shorter than 355 nm is impractical because it is difficult to handle. Accordingly, the lower limit of the groove track pitch can be 0.2 μm.

The transfer pattern sample of the present invention can be played back by using the RRO evaluation apparatus as described above. In this embodiment, Pulstec DDU-1000 was used. The laser wavelength was 405 nm, and the NA was 0.65.

The method of evaluating the RRO of a transfer pattern sample will now be explained.

A transfer pattern sample was set in the above-mentioned evaluation apparatus and rotated at a linear velocity of 1.2 m/s. Note that the linear velocity tends to decrease as the frequency rises (the servo gain characteristic) because the apparatus has the tracking characteristic. When the linear velocity is a lowest velocity equal to or higher than the minimum rotational speed of the spindle motor, therefore, a high-order component of the RRO can be checked more accurately by amplifying the displacement amount of the order. In this evaluation apparatus, one rotation of the disk is converted into a frequency as a rotational frequency, and the eccentric order is represented by this rotational frequency.

A laser was emitted, and the tilt and offset were adjusted such that the difference signal (push-pull signal) was maximum, thereby performing tracking. The frequency of the push-pull signal after tracking was analyzed using an FFT analyzer (CF-5210 manufactured by Ono Sokki).

Then, the peak-to-peak value of the same push-pull signal was checked while tracking was turned off and only focusing was adjusted. This peak-to-peak voltage value is equivalent to a half-track pitch displacement amount. The displacement amount was calculated by dividing the voltage value at each frequency measured by the FFT analyzer by the peak-to-peak voltage value. Note that the measurement conditions of the FFT analyzer were that data obtained by measuring one track 100 times and averaging the results was regarded as one measurement, and a maximum value of the results of five measurements performed by changing tracks in a dummy area was regarded as the displacement amount. This calculation result was used as the RRO of the transfer pattern sample in the present invention. Assuming that the rotational frequency of the transfer pattern sample was the first-order displacement amount as a reference, attention was particularly given to the 15th- to 40th-order displacement amounts. When the order is less than 15th, an error readily occurs owing to a position where a transfer pattern sample is placed. Also, a certain stable displacement amount is obtained without performing measurement exceeding the 40th order.

Although a transfer pattern sample by which the ratio of the land to the groove was 1:1 was used in the above example, the present invention is not limited to this. The characteristics of the apparatus for checking the RRO characteristic make tracking impossible to perform if PP/SUM<0.1 where PP/SUM is a value obtained by normalizing an amplitude (p−p) of a push-pull signal PP by a voltage value (p−G) of a sum signal SUM. Accordingly, it is possible to select a land-to-groove ratio at which tracking can be performed by preventing this.

Examples 1-12 & Comparative Examples 1-11

Magnetic recording media were manufactured by transferring patterns onto magnetic recording layers by the above method by using ultraviolet-curable resins A to Y.

Table 1 shows the contents of ultraviolet-curable resins A to Y, and Table 2 shows the results.

Symbols in Table 1 will be explained below.

IBOA: Isobornyl acrylate

TITA: Tris(2-hydroxyethyl)isocyanurate triacrylate

IRGACURE369: 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butanone-1

EGTA3: Ethoxylated (3) glyceryl triacrylate

wherein l+m+n=3 in formular (4) above

EGTA9: Ethoxylated (9) glyceryl triacrylate

l+m+n=9 in formula (4) above

EGTA20: Ethoxylated (20) glyceryl triacrylate

l+m+n=20 in formula (4) above

TMPTA: Trimethylolpropane triacrylate

TMPTA-3EO: Ethoxylated (3) trimethylolpropane triacrylate

wherein l+m+n=3 in formula (6) above

PUHA: Polyurethane hexaacrylate

wherein n=25

TCDMA: Tricyclodecanedimethanol diacrylate

PEA: 2-phenoxyethyl acrylate

PBFA: Propoxylated bisphenol A glycidyl etherified acrylate

DTMPTA: Ditrimethylolpropane tetraacrylate

Ultraviolet-curable resins A to K and Y were found to be ultraviolet-curable resins suitably used to transfer patterns onto a magnetic recording medium in respect of all of the viscosity, property of separation, curing property, film thickness, etching rate, and RRO.

Among others, C, D, F, G, J, and Y were particularly superior in etching rate.

When using trifunctional acrylates having the same skeleton, the etching rate decreased as an ethoxy group was increased, so the etching resistance increased.

A, C, G, and Y were particularly superior in curing property.

For the film thickness, Y having a lowest viscosity was best, and A, D, F, G, and J were also good.

On the other hand, L, N, O, R, U, and X were bad in curing property. In particular, X containing no polymerization initiator did not cure at all. M and N were inferior in etching resistance, and N, P, Q, R, and S caused large cure shrinkage because they were bad in RRO.

The above results indicate that the ultraviolet-curable resin containing 80 to 95 wt % of isobornyl acrylate, 1 to 20 wt % of trifunctional acrylate, and 0.5 to 6 wt % of a polymerization initiator are superior in ultraviolet curing property, property of separation after curing, etching resistance, and cure shrinkage. The above results also demonstrate that accurate pattern transfer can be performed from a stamper when using the ultraviolet-curable resin material for pattern transfer as described above.

Furthermore, the contents of the IBOA, trifunctional acrylate, and polymerization initiator can particularly be 85 to 93 wt %, 6 to 10 wt %, and 1 to 5 wt %, respectively.

It was possible to obtain favorable characteristics when forming DTR media by using good ultraviolet-curable resins and checking the recording/reproduction characteristics.

Note that although Irgacure 369 was used as the polymerization initiator in the examples, but it is naturally possible to appropriately select any polymerization initiator in accordance with the affinity to the UV lamp or acrylate.

TABLE 1 Trifunctional Polymerization Resin Acrylate acrylate initiator Example 1 A IBOA 90 wt % TITA(6 wt %) IRGACURE369 4 wt % Example 2 B IBOA 90 wt % EGTA3(6 wt %) IRGACURE369 4 wt % Example 3 C IBOA 90 wt % EGTA9(6 wt %) IRGACURE369 4 wt % Example 4 D IBOA 90 wt % EGTA20(6 wt %) IRGACURE369 4 wt % Example 5 E IBOA 90 wt % TMPTA(6 wt %) IRGACURE369 4 wt % Example 6 F IBOA 90 wt % TMPTA-3EO(6 wt %) IRGACURE369 4 wt % Example 7 G IBOA 85 wt % TMPTA-3EO(10 wt %) IRGACURE369 5 wt % Example 8 H IBOA 80 wt % TMPTA-3EO(15 wt %) IRGACURE369 5 wt % Example 9 I IBOA 90 wt % TMPTA-3EO(8 wt %) IRGACURE369 2 wt % Example 10 J IBOA 95 wt % TMPTA-3EO(4 wt %) IRGACURE369 1 wt % Example 11 K IBOA 80 wt % TMPTA-3EO(18 wt %) IRGACURE369 2 wt % Comparative Example 1 L IBOA 98 wt % TMPTA-3EO(1.5 wt %) IRGACURE369 0.5 wt % Comparative Example 2 M IBOA 84 wt % PUHA 10 wt % IRGACURE369 6 wt % Comparative Example 3 N IBOA 90 wt % TCDMA 6 wt % IRGACURE369 4 wt % Comparative Example 4 O PEA 92 wt % PBFA 5 wt % IRGACURE369 3 wt % Comparative Example 5 P IBOA 90 wt % DTMPTA 6 wt % IRGACURE369 4 wt % Comparative Example 6 Q IBOA 77 wt % TMPTA-3EO(21 wt %) IRGACURE369 2 wt % Comparative Example 7 R IBOA 77 wt %/ TMPTA-3EO 0.8 wt % IRGACURE369 2.2 wt % PEA 20 wt % Comparative Example 8 S IBOA 78 wt % TMPTA-3EO 21 wt % IRGACURE369 1 wt % Comparative Example 9 T IBOA TMPTA-3EO(10 wt %) IRGACURE369 6.5 wt % 83.5 wt % Comparative Example 10 U IBOA 88 wt % TMPTA-3EO(12.6 wt %) IRGACURE369 0.4 wt % Comparative Example 11 X IBOA 88 wt % TMPTA-3EO(13 wt %) IRGACURE369 0 wt % Example 12 Y IBOA 93 wt % TMPTA-3EO(6 wt %) IRGACURE369 1 wt %

TABLE 2 Viscosity Property of Curing Film RRO Resin (CP) separation property thickness (nm/sec) (nm) Example 1 A 11 ◯ ⊚ 44 0.24 ◯ 0.4 Example 2 B 10 ◯ ◯ 53 0.20 ◯ 0.7 Example 3 C 10 ◯ ⊚ 48 0.12 ◯ 0.5 Example 4 D 10 ◯ ◯ 42 0.12 ◯ 0.7 Example 5 E 10 ◯ ◯ 47 0.16 ◯ 0.6 Example 6 F 10 ◯ ◯ 43 0.12 ◯ 0.5 Example 7 G 13 ◯ ⊚ 44 0.11 ◯  0.75 Example 8 H 14 ◯ ◯ 58 0.13 ◯ 0.9 Example 9 I 11.5 ◯ ◯ 52 0.14 ◯ 0.7 Example 10 J 9.5 ◯ ◯ 37 0.10 ◯ 0.5 Example 11 K 15 ◯ ◯ 59 0.16 ◯ 1.0 Comparative L 9 ◯ X 32 0.12 ◯ Immeasurable Example 1 Comparative M 13 ◯ Δ 54 0.26 X 0.4 Example 2 Comparative N 10 ◯ X 47 0.27 X 1.2 Example 3 Comparative O 11 ◯ X 52 0.12 ◯ 0.8 Example 4 Comparative P 16 ◯ ⊚ 62 0.18 ◯ 1.5 Example 5 Comparative Q 19 ◯ ⊚ 67 0.17 ◯ 1.1 Example 6 Comparative R 9.3 Δ X 45 0.14 ◯ 1.2 Example 7 Comparative S 18 Δ ⊚ 68 0.20 ◯ 1.2 Example 8 Comparative T 16 ◯ Δ 61 0.21 ◯ 0.8 Example 9 Comparative U 10 ◯ X 48 0.16 ◯ Immeasurable Example 10 Comparative X 9.5 ◯ X Immeasurable Immeasurable Immeasurable Example 11 Example 12 Y 9.3 ◯ ⊚ 36 0.10 ◯ 0.4

While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions. 

1. An ultraviolet-curable resin material for pattern transfer comprising: 80 to 95 wt % of an isobornyl acrylate; 1 to 20 wt % of a trifunctional acrylate; and 0.5 to 6 wt % of a polymerization initiator.
 2. The material of claim 1, wherein the material has a viscosity of 9 to 15 cP at 25° C.
 3. A magnetic recording medium manufacturing method comprising: contacting, under a vacuum, a surface of a magnetic recording layer of a magnetic recording medium comprising a data area and a servo area, and a three-dimensional pattern surface of a resin stamper, with a coating layer of an uncured ultraviolet-curable resin material for pattern transfer comprising 80 to 95 wt % of isobornyl acrylate, 1 to 20 wt % of trifunctional acrylate, and 0.5 to 6 wt % of a polymerization initiator interposed between the surface of the magnetic recording layer and the three-dimensional pattern surface; curing the coating layer of the uncured ultraviolet-curable resin material by ultraviolet irradiation; separating the resin stamper to form, on one surface of the magnetic recording medium, a cured ultraviolet-curable resin material layer comprising a transferred three-dimensional pattern; and dry etching with the cured ultraviolet-curable resin material layer as a mask, thereby forming a three-dimensional pattern on the surface of the magnetic recording layer.
 4. The method of claim 3, wherein the uncured ultraviolet-curable resin material for pattern transfer has a viscosity of 9 to 15 cP at 25° C. 